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XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
High efficiency supermarkets: BLDC compressors and waterloop
Tommaso Ferrarese – HVAC/R Laboratory, Carel Industries S.p.A. Giacomo Bagarella – PhD Energetic Engineering, University of Padua
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Refrigerant leakages and power consumption in supermarkets
Refrigeration systemLightingHVACMiscellaneous
7%
18%
21%
54%
15%
20%
8%
36%
21%
MT compressorsLT compressorsAircooled condensersDisplay case fans/lightsDefrost & anti-sweat heaters
Refrigerant Charge
3.5 ÷ 4 kg/kW
Refrigerant leakages
10% ÷ 15%
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Waterloop solution
BLDC compressor onboard, inverter driven
Condenser and inverter electronics are cooled by water
Electronic expansion valve
Reverse cycle defrost available
Inverter driven BLDC compressor allows flexibility, high efficiency in part load operation and optimal temperature control
No need of 3phase power supply for each cabinet. Heat produced during defrost can be recovered by the water loop
Stand-alone cabinet
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Waterloop solutionWaterloop plant
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Charge and leakages reduction
Leakage reduction: from 10%-15% to 1-2%
Charge Reduction over 70%:From 3.5 ÷ 4 kg/kW to 1 kg/kW
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Energy efficiency
In traditional supermarkets suction pressure setpoint depends from «worst» conditions: maximum cooling power demand
A centralized system with floating suction can increase the setpoint when the cooling demand is lower, but it always depends on the «worst» unit
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Energy efficiency
Each self contained cabinet can operate with the maximum evap T allowed
When load ratio is less than 1 the inverter compressor reduces its speed and works with a higher Evap T than in traditional systems
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Costs
Stand-alone units are more expensive than standard onesCooling devices installed on the waterloop are standard
AC units, available on the market, reliable and operating in more efficient conditions
Copper pipes are replaced by hydraulic pipesNo need of pipe insulationCharge reductionMore flexibility in plant architectureHigh reliabilty due to factory assembled unitsRunning costs reduced by higher efficiency and easy
maintenance
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Medium Temp
UnitsControl Devices
CpsCool.Cap.
[kW]Low Temp Units
Control devices
CpsCool.Cap. [kW]
Vegetables 2 2 2 3780Frozen
food6 6 6 9500
Dairy 6 6 6 20800 Cells 2 4 4 4200Meat 3 3 3 9700 Total 8 10 10 13700
Fish 2 4 2 2780Comp.
cool. cap.Evap T: -35°C Evap T: -10°C
Deli 6 8 3 9080 Small 800 2200Cold rooms 7 7 4 13600 Medium 1300 3600
Total 26 30 20 59740 Large 1700 4500
Real supermarket plant
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Supermarket simulation
Data Acquisition
Energetic Model(Water-Loop
Solution)
RealSupermarket
Energetic Model(Traditional
Supermarket)
Condensation: FixedEvaporation: Fixed
SimulationsEnergetic Model(Advanced
Supermarket)
Energetic ModelR134a/CO2
Cascade
Weather Data(Berlin)
Cooling Loads
Condensation: FloatingEvaporation: Floating
Condensation: FloatingEvaporation: Floating Energy
Analysis
Energetic Model
Model Validation
Superm
arket Area 3000 m
2
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Supermarket simulation
Medium Temperature
CabinetsCooling
capacity [W]Low
TemperatureCabinets
Cooling capacity [W]
Vegetables 6 10000 Frozen food 24 35000
Dairy 18 60000 Cells 6 20000
Meat 8 26000 Total 30 55000
Fish 6 8000
Deli 18 26000
Cold rooms 8 35000
Total 64 165000
MT/LT Comps
MT/LT Cool. Capacity [kW]
MT/LT Electric Power [kW]
MT/LT Evap T [kW]Cond T
[°C]Waterloop
solution72/30 170/60 79/34 Variable/Variable 20
Traditional Supermarket
6/3 200/64 87/53 -10/-35 33
Advanced Supermarket
6/3 200/64 87/53 Variable/Variable Variable
R134a/CO2 Cascade
7/3 270/78 100/22 Variable/Variable Variable
Reference
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Supermarket simulationEnergy efficiency
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Supermarket simulationEnergy efficiency
Energy absorbed
[kWh/year]Energy saved
[kWh/year]Energy saving
Money saving [€/year] MIN
Money saving [€/year] MAX
Waterloop solution BLDC
418500 - - -
W.loop fixed speed Comp
458200 39700 9% 5955 9925
Traditional Supermarket
592400 173900 29% 26085 43475
Advanced Supermarket
457000 38500 8% 5775 9625
R134a/CO2 Cascade
466000 47500 10% 7125 11875
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Supermarket simulationTEWI
CO2 indirect [t CO2/10 yrs]
CO2 direct [t CO2/10 yrs]
C02 End of Life [t CO2]
TEWI [t CO2/ 10 year]
Waterloop solution
4425 72 36 4533
Traditional Supermarket
5469 19% 4560 98% 152 76% 10181 55%
Advanced Supermarket
4656 5% 4560 98% 152 76% 9368 52%
R134a/CO2 Cascade
4711 6% 936 92% 31 -15% 3764 20%
XV EUROPEAN CONFERENCE MILANO 7th-8th JUNE 2013 CSG
Latest Technology in Refrigeration and Air Conditioning Under the Auspices of the PRESIDENCY OF THE COUNCIL OF MINISTERS
Thank you for your attention!